Electrically heated sock with battery supporting pouch



8- 1968 D. J. MURPHY ET AL 3,396,264

ELECTRICALLY HEATED SOCK WITH BATTERY SUPPORTING POUCH Filed Sept. 8,1967 2 Sheets-Sheet 1 INVENTOR Dennis Murphy Charles F Balz wfw ATTORNEY6, 1968 o. J. MURPHY ET AL 3,396,264

ELECTRICALLY HEATED SOCK WITH BATTERY SUPPORTING POUCH 2 Sheets-Sheet 2/j INVENTOR Dennis Murphy Charles F Balz BY Filed Sept. 8, 1967 ATTORNEYUnited States Patent 3,396,264 ELECTRICALLY HEATED SOCK WITH BATTERYSUPPORTING POUCH Dennis J. Murphy, Fishkill, and Charles F. Balz,Beacon,

N.Y., assignors to Timely Products Corporation, a corporation ofConnecticut Filed Sept. 8, 1967, Ser. No. 666,412 13 Claims. (Cl.219-211) ABSTRACT OF THE DISCLOSURE An electrically heated sock having apouch generally integrally formed of a sheet of blank material which isspecifically die cut and folded to define a pocket having a flap forencasing a battery therein and having contacts arranged to providepositive contact with the electrodes of the battery disposed within thepouch when the flap is closed.

THE PROBLEM IN THE ART In the construction of low voltage,battery-energized electrically heated socks of the wholly self-containedtype wherein the battery was supported by and/or adjacent the upper endportion of the sock, considerable difficulty has been heretoforeencountered providing a proper support or attachment for the battery. Inthe early development of this type of self-contained battery-operatedsock, a pocket was knitted or woven into the hem portion of the sock todefine an integrally formed pouch for receiving the battery. However,the knitting and/ or forming of a pouch or pocket as an integral part ofthe sock during the manufacture of the sock introduced severemanufacturing problems into the construction of the sock which greatlyincreased the cost thereof and which would have necessitated substantialchanges in the knitting machines. Also it has been discovered inpractice that relatively complex battery-holding brackets werenecessitated to connect the battery into circuit with the heater portionof the sock when the battery was placed in the knitted pocket of thesock. Accordingly, the integrally woven pocket in the hem portion of thesock has proven to be an entirely unsatisfactory manner for supportingthe battery on the sock.

Other known efforts to support the battery for energizing suchelectrical socks comprised the complete separation of the batterysupport from the sock. This means included the construction of aseparate knitted pocket or pouch which was strapped to the leg by aconnected garter band and the battery for energizing the heater of thesock carried therein. However, this construction has not provensatisfactory for the reason that such construction detracted from thedesirably wholly self-contained feature of the electric sock as suchconstruction required the sock to be constructed in two separate anddistinct parts which required interconnecting extended wire conductorsand detachable contacts for creating the circuit between the batterycarried in the remotely positioned pouch and the electric heater carriedin the toe portion of the sock. With this type of two-piececonstruction, experience has shown much difficulty to be encountered inmaintaining proper and positive electrical contact between the batteryand the heater of the sock. This two-piece construction alsonecessitated a relatively complex auxiliary battery holder or bracket tosupport the battery within the remotely disposed knitted pocket or pouchin electrical contact with the heater of the sock. Thus the structureand cost of such auxiliary battery holder or bracket greatly increasedthe cost and manufacturing effort of such electric socks.

3,396,264 Patented Aug. 6, 1968 OBJECTS OF INVENTION An object of thisinvention is to provide an improved pocket or pouch construction inwhich the need for an auxiliary holder or bracket for the battery iscompletely eliminated.

Another object of this invention is to provide an improved pouchconstruction which can be readily secured adjacent the upper end portionof the sock so as to enable one to wear the sock in comfort in a mannerso as to render the presence of the battery unnotice-able.

Another object of this invention is to provide a battery pouch for anelectrical sock having built-in contacts which can be formed from asingle sheet of foldable blank material, which when folded snuglyreceives and supports the battery in electrical contact with the heater.

Another object of this invention is to provide a battery pouchconstruction having electrical contacts incorporated therein which canbe readily manufactured with a minimum of cost and/ or difiiculty.

Another object of this invention is to provide an improved pouchconstruction wherein its construction is such that positive electricalcontact is insured between the battery and the heater of the sock.

Another object of this invention is to provide a blank constructionwhich when folded forms an integral pouch construction having a closureflap which is adapted to be utilized as a switching means for making andbreaking the circuit between the battery and the electric heater portionof the sock.

Another object of this invention is to provide an improved pouchconstruction which can be directly secured to the upper end portion ofthe sock in a manner so that the weight of the battery is supported onthe leg of the wearer.

SUMMARY OF INVENTION The foregoing objects and other features andadvantages of this invention are attained by a pouch construction formedof a single blank of foldable material which is die cut and formed todefine an integrally connected back wall forming portion terminating inouter marginal portions and a front wall portion, the respective frontand back wall forming portions being interconnected by an intermediateconnecting web portion. The front wall portion has laterally extendingconnected side wall forming portions which are rendered foldablerelative to the front wall portion about opposed fold lines so that inthe folded position of the blang a pocket is defined thereby. The sidewall portions in turn are each provided with outer marginal portionsarranged, when folded, to be disposed into contiguous overlyingrelationship to the outer marginal portions of the back wall port-ion ofthe pouch. Means are provided for securing the overlying marginalportions of the back wall forming part of the blank with the outermarginal portions connected to the side wall portions of the blank tomaintain the blank in pouchforming position. The blank constructionfurther includes an integral flap portion connected about a fold line tothe upper end portion of the blank back wall portion, and a fasteningmeans in the form of a stretchable tongue, and complementary fastenerscarried on the tongue and on the front wall of the form pouch isprovided for maintaining the flap in a closed position. If desired, anelastic band or garter is suitably connected to the pouch so that thesame may be strapped about the leg of the wearer of such socks to assistin supporting the weight of the battery to ones leg.

Contact means are provided in the pouch to maintain the battery incircuit with the heater of the sock. One contact is disposed on thebottom of the pouch, and a second or complementary contact carried onthe flap portion of the pouch, the arrangement being such that when theclosure flap is secured in its closed position, the electrodes of thebattery is positively sandwiched and in contact between the opposedcontacts of the pouch. In operation the flap functions as a switch formaking and breaking the circuit to the heater of the sock.

A feature of this invention resides in the provision of a battery pouchformed of a single sheet of foldable material in which the adjacentmarginal portions of the folded may be suitably sealed or secured todefine an integral pouch.

Another feature of this invention resides in the provision of a batterypouch for an electric sock which is relatively simple in construction,which can be easily fabricated, and which is relatively inexpensive tomanufacture.

Another feature of this invention resides in a single blank constructionwhich can be readily formed and secured into a pouch-forming pocket forsnugly receiving the battery therein wherein the need or use of anauxiliary battery holding means is completely obviated.

Another feature of this invention resides in a battery pouchconstruction wherein the closure flap thereof functions as a switchingmeans for making and breaking the circuit to the heater.

Another feature of this invention resides in the provision of means forpositively sandwiching the battery in electrical contact between theelectrical contacts of the battery pouch.

Other features and advantages will become more readily apparent whenconsidered in view of the drawings and specification in which:

FIG. 1 illustrates a perspective view of the battery pouch constructionof this invention as applied to an electrically heated sock, portions ofwhich are broken away.

FIG. 2 illustrates a plan view of the blank construction from which thebattery pouch of FIG. 1 is fabricated.

FIG. 3 illustrates the blank construction of FIG. 1 in an intermediatefolded position.

FIG. 4 illustrates a detail sectional side view of the battery pouchconstruction taken along line 44 on FIG. 1 with the battery removed.

FIG. 5 is a sectional front view taken along line 55 on FIG. 4.

FIG. 6 illustrates a back view of the pouch construction of FIGS. 4 and5.

FIG. 7 illustrates a cross-sectional view of the pouch construction ofFIGS. 4 through 6 in which the closure flap of the pouch is illustratedin the closed position thereof.

Referring to the drawings, there is shown in FIG. 1, the improved pouchconstruction 10 embodying the invention herein as applied to a heatedsock 11. The sock 11 is illustrated as a conventionall formed sock, forexample, a woven or knitted sock that comprises generally a toe portion11A, a heel portion 11B and a connected leg portion 11C, the upper endof which may be provided with suitable elastic hem or cuff 11D. Theconstruction and manufacture of the illustrated sock is conventional,with the exception that an electrical heater 12 is disposed in the toeportion 11A of the sock as disclosed in US. Patent No. 3,293,405. Asdescribed, in US. Patent No. 3,293,405, the electrical heater 12 issuitably connected to electrical conductors 13, 14 which extend up theleg portion of the sock, and which electrical conductors terminate atelectrical contacts carried on the pouch as will be hereinafterdescribed. Accordingly, it will be noted that the sock 11 iselectrically heated by means of an electrical resistance material whichis energized by a low voltage battery 15, as for example a battery ofsix volts or less such as a flashlight battery.

In accordance with this invention the battery 15 is suitably carried inan improved pouch construction 10 which is preferably secured to thesock 11 adjacent the upper end 11D thereof by any suitable means, e.g.,sewing. The

improved pouch construction 10 for supporting the battery 15 adjacentthe upper end of the sock to form a Wholly self-contained electricallyheated sock comprises essentially a single blank of sheet material 16which is shaped and die cut as illustrated in FIG. 2. The blank 16 maybe formed of any suitable foldable sheet material. However, it ispreferred that the blank 16 be formed of a suitable, heat-scalableplastic material.

As shown in FIG. 2 the blank construction 16 comprises a sheet materialhaving laterally extending step portions as indicated. The blank 16includes a back wallforming portion 17 and a front wall portion 18interconnected by an intermediate bottom web portion 19. The bottom webportion 19, as indicated, is provided with opposed L-shaped die cuts 20,which in the folded position of the blank, as will be hereinafterdescribed, define side wall bottom flaps 21.

As shown, the front wall portion 18 has connected along the opposedlongitudinal edges thereof about fold lines F and F opposed sidewall-forming portions 23, 24 which are adapted to be folded relative tothe front wall portion 18 about respective fold lines F and F Each ofthe respective side wall portions 23, 24 terminates in a laterallyextending marginal portion 23A, 24A which in the folded position of theblank, as illustrated in FIG. 3, are arranged to overlie the marginalend portions 17A, 17B of the back wall portion of the blank. Connectedto each side wall portion is a side wall bottom flap 21, 22 foldableabout fold lines F and F.,. In the illustrated form of the blank, FIG.2, it will be noted that the outer marginal portions 17A, 17B of theback wall-forming portion and the marginal portions 23A, 24A connectedto the side wall-forming portions are each provided with relativelysmall apertures 25 which function as means to effect alignment formaintaining the respective portions of the blank in a pre-assembledintermediate step to facilitate the manufacture and assembly thereof.Accordingly, the pouch is constructed by first forming and die-cuttingthe blank 16 as illustrated in FIG. 2, and the blank 16 thus formed isthen reversely folded about fold lines F and F to dispose the frontportion 18 of the blank in spaced relationship to the back portion 17 ofthe blank as best seen in FIG. 2. In this position the side portions 23,24 of the pouch are formed about their respective fold lines with theside marginal portions 23A, 24A laterally folded to overlie the marginalportions 17A, 17B of the back wall-forming portion, as in FIG. 2. Inthis intermediate folded position it will be noted that the bottom sidewall-forming flaps 21, 22 are folded inwardly about their respectivefold lines F F as best seen in FIGS. 4 and 5. This allows the bottomside Wall flaps 21, 22 to be folded in overlying relationship above thebottom Webforming portion 19 of the blank. Accordingly, as seen in FIGS.4 and 5, the bottom of the pouch is defined by a triple layer ofmaterial which includes the bottom web portion 19 and the opposed sidebottom flaps 21, 22.

To secure the overlying marginal portions 17A, 17B and 23A, 24A to formthe integral pouch construction, it will be noted that a heat-seal seam26 is formed by suitable means which integrally fuse the marginalportions together. In the sealing operation the marginal portionsextending beyond the outermost seam (FIG. 3) may sever, thus forming thepouch construction as seen in FIGS. 1 and 5.

In accordance with this invention a closure flap 27 is integrally formedto the back wall 17 of the pouch to form an extension thereof. The flap27 is sufiiciently long so that when folded it forms a closure for theopen end of the pocket or pouch defined by the folded blank, as bestseen in FIG. 7. If desired, the corner portion 27A of the flap 27 may beout along the dotted lines as shown on FIG. 3 to shape the flap as shownin FIGS. 5 and 6. It will be noted that the size of the blankconstruction is specifically prescribed so that in the folded positionthereof a pocket is defined which will snugly receive the battery bywhich the electrical heater of the sock is energized.

In accordance with this invention it will be noted that the bottomforming web portion 19, and each of the respective bottom side formingfiaps 21, 22 are provided with an aperture 28 which in the foldedposition of the blank is disposed in alignment, as best seen in FIGS. 4and 5.

In the illustrated form of the invention the battery 15 comprises aconventional flashlight battery which may generate a voltage of 1 /2volts.

The battery pouch is provided with suitable contacts by which thebattery supported or carried therein is connected into electricalcircuit with the heater of the sock construction. As shown, a plate 29formed of suitably conducting material is disposed in the bottom of thepocket and it is arranged to rest upon the uppermost of the bottom-forming side wall flaps, as is best illustrated in FIGS. 4 and 5.Preferably the contact plate 29 comprises a disc which rests on thebottom of the pouch. The electrical conductor 13, which connects thedisc contact 29 into circuit with the heater 12, is threaded through thealigned openings 28 provided in the respective bottom flaps and bottomwall portion of the pouch. Thus when the battery is disposed in thepouch, one electrode engages the contact disc as seen in FIG. 7. Thecomplementary contact for connecting the other electrode of the batteryinto circuit with the heater comprises a button-type contact 30 which iscarried on the closure flap portion of the pouch. As best seen in FIG.7, it will be noted that when the closure flap 27 is secured in theclosed position, the button contact 30 is disposed against the end orother electrode of the battery. Accordingly, as best seen in FIG. 7,with the closure flap 27 drawn to its closed position, the battery 15 ispositively sandwiched between the contact disc 29 and button contact 30to place the battery in circuit to the heater 12. The conductor 13, 14connecting the button contact 30 in circuit to the heater is threadedthrough an opening 31.

In order to insure that the battery is secured between the respectivecontacts 29 and 30 so as to insure positive electrical contact with theterminals or electrodes of the battery a stretchable tongue 32 ofelastic material is connected to the free end of the flap 27 andsuitable fastening means are provided for securing the stretchabletongue 32 to the wall of the pouch to maintain the flap in the operativeclosed position as in FIG. 7.

In the illustrated form of the invention the fastening means comprisecomplementary male and female snaptype fasteners 33, 34, one of which iscarried adjacent the free end of the stretchable elastic tongue and theother complementary fastening means being carried on the front wallportion of the pouch adjacent the lower end thereof. As best seen inFIG. 7 it will be noted that in order to align the complementaryfasteners 33, 34 to effect the engagement thereof, the tongue 32 must beslightly stretched so that the tension thus provided assures that asufficient force is maintained by the closure flap 27 against the end ofthe battery to insure positive electrical contact between the opposedcontacts 29, 30, and the respective battery electrodes.

Because the dimensions of the blank sheet are specifically predeterminedto define in the folded position thereof a pouch construction for snuglyreceiving the battery, it will be noted that the need for any auxiliarybattery holding bracket is completely obviated.

As best seen in FIG. 1, it is preferred that the battery pouch 10construction defined be suitably secured to the upper end portion of thesock by any suitable means, for example, by a sewn seam or the like. Ifdesired, an elastic band or garter 36 may be secured to the pouchconstruction 10 whereby the weight of the battery can be furthersupported on the leg of the wearer by strapping the pouch about the legof the wearer. The band or garter 36 thus connected to the pouchconstruction may also function as a garter for the sock.

While the instant invention has been described with respect to aparticular embodiment thereof, it will be readily appreciated andunderstood that variations and modifications may be made withoutdeparting from the spirit or scope of the invention. For example, inaddition for use with electric socks as herein described, the batterypouch may be used with other battery-operated heated garments or otherbattery-operated devices. For example, the pouch may be satisfactorilyused with battery heated gloves, sweaters, shirts, pants and variousarticles of clothing.

What is claimed is:

1. An improved pouch construction adapted for securing a low-voltagebattery to the hem portion of a battery-actuated, electrically heatedsock comprising:

a sheet of blank material adapted to be folded to form an integrallyconstructed pouch,

said sheet including an integrally connected back wall having outermarginal portions and front wall portion,

a web portion interconnecting said front and back wall portion,

and said front wall portion having laterally extending connected sidewall forming portions which in the folded portion of the blank definethe side walls of the pouch construction,

said side wall portions having outer marginal portions arranged whenfolded to be disposed in contiguous overlying relationship to the outermarginal portions of said back wall portion,

and means securing said overlying marginal portions of said back wallforming portion and said outer marginal portions connected to said sidewall forming portions to maintain said blank in pouch-forming position,

a flap portion connected about a folding to the upper end of said backwall portion,

and fastening means for detachably securing said flap portion to saidfront wall portion in the operable position of said pouch.

2. The pouch construction as defined in claim 1 wherein said blank isformed of a plastic heat fusible material.

3. The invention as defined in claim 2 wherein said means for securingthe overlying marginal portions of said back forming portion and saidouter marginal portions connected to said side wall portions include aheat fusible seam.

4. The pouch construction as defined in claim 1 wheresaid web portion isdie cut to define a bottom web portion interconnected between said backportion and front portion,

and a pair of opposed bottom side wall flaps hingedly connected about afoldline to said side portions, whereby in the folded position of saidblank, the side wall bottom flaps are folded in overlying relationshipcontinuous to said bottom web portion to define a reinforced triplelayer bottom Wall for said pouch.

5. The pouch construction of claim 1 wherein each of said bottom webportions and side wall bottom flaps are provided with an apertureposition therein so that in the folded position of the blank, saidapertures are disposed in alignment.

6. The invention as defined in claim 5 and including an electricalconducting contact located in the bottom of said pouch, and a wireconductor electrically connected to said contact,

said conductor being threaded through said aligned apertures in theassembled position of said pouch.

7. The invention as defined in claim 6, and including an electrical topcontact secured to an intermediate portion of said flap, whereby saidtop contact is adapted to make contact with an electrode of a batteryadapted to be supported in said pouch.

8. The invention as defined in claim 1 wherein said fastening meansincludes:

a stretchable tongue connected to said flap,

and complementary mating fasteners connected adjacent the free end ofsaid tongue and the front wall portion whereby the flap is disposed insnug relationship to the end of the battery adapted to be disposedwithin said pouch.

9. The invention as defined in claim 8 and including complementaryelectrical contacts for connecting a battery within said pouch inelectrical contact when said flap is secured.

10. The invention as defined in claim 9 wherein a contact is connectedto said flap portion to engage an electrode of a battery disposed insaid pouch and another contact disposed in the bottom of said pouch toelectrically contact the other electrode of said battery.

11 The invention as defined in claim 1 and including an elastic bandconnected to said pouch for securing the same about the leg of a wearer.

12. A low voltage, battery-operated, electrically heated sock,comprising in combination:

a sock having a toe portion, a heel portion, and a connected legportion,

a heater disposed in the toe portion of said sock, said heater includinga strip of electrical resistance material,

and a battery pouch disposed adjacent the upper end of said sock adaptedfor supporting the battery for energizing said heater,

said battery pouch including a blank of heat fusible plastic material,

said blank including integrally connected back wall portion and a frontwall portion, said back wall portion having outer marginal portions,

a bottom forming web interconnecting said back Wall portion to saidfront wall portion,

a side wall portion connected to each side of said front wall portionabout a foldl-ine,

each of said side wall portions having a connected laterally extendingouter marginal portion,

said blank being reversely folded so that the marginal portion of saidside walls contiguously overlies the marginal portions of said back wallportions,

a heat fusible seam securing said side wall marginal portions to theback wall marginal portion,

side wall bottom flaps connected to each of said side wall portions,

said side wall bottom flaps in the folded portion of said blank beingdisposed in contiguous overlying relationship to said bottom forming webin the folded position of said blank,

each of said bottom flaps and bottom web portions having alignedapertures formed therein,

a closure flap hingedly connected to said back portion about a foldline,

an elastic tongue connected to said closure flap,

complementary fastening means on said tongue and said front wall portionfor detachably securing said closure flap in the closed position,

an electrical contact disposed in the bottom of said pouch,

and a second electrical contact connected to said flap,

said contacts being adapted to sandwich said battery therebetween whensaid closure flap is secured,

and electrical conductors connecting each of said contacts in circuitwith said heater whereby said heater is energized only when said closureflap is secured to said front wall portion,

means securing said pouch adjacent the upper end of the connected legportion of said sock,

and an elastic band connected to said pouch for supporting the Weight ofthe battery therein on the wearers leg.

13. A battery pouch construction comprising:

a blank of readily foldable material including a back panel and a frontpanel, and a web portion interconnecting said back and front panels,

said front panel having connected side wall forming portions in thefolded position of the blank,

each of said side wall forming portions having an outer laterallyextending marginal portion adapted in the folded position of said blankto be disposed in contiguous overlying relationship to the marginalportions of said back panel,

means securing said overlying marginal portions together to define abattery receiving pocket,

a flap connected to the upper end of said back panel, said flap beingadapted to fold over the open end of the pocket defined in the foldedposition of said blank,

fastening means for securing said flap to the front panel,

an electrical contact secured to the said flap so that in the folded andfastened position, said contact is disposed in contact with an electrodeof a battery disposed in the pouch,

and a second contact positioned in the bottom of said pocket to engagethe other electrode of said battery.

References Cited UNITED STATES PATENTS 2,584,302 2/1952 Stein 219-5272,692,326 10/1954 Crowell 219-211 3,079,486 2/1963 Winchell 219-5283,084,241 4/1963 Carrona 219-211 3,293,405 12/1966 Costanzo 219-211BERNARD A. GILHEANY, Primary Examiner. VOLODYMYR MAYEWSKY, AssistantExaminer.

